Bulk fill material

ABSTRACT

Among other things, the inventive subject matter generally relates to bulk fill materials suitable for an insulative or cushioning material. The bulk fill material consists of a plurality of discrete units comprising clusters or loose webs of fibers. The fibers consist of superfine fibers and/or fibers in a range of 1 to 5 denier; the fibers being entangled to form the clusters or loose webs. In some embodiments the clusters or webs are multinode fiber structures that mimic natural down. The inventive subject matter is also directed to related methods of production.

RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.14/987,684 filed Jan. 4, 2016, which claims the benefit of and priorityto PCT Application Serial Number PCT/US2014/045484 filed Jul. 3, 2014,U.S. Provisional Application Ser. No. 61/843,295, filed Jul. 5, 2013,U.S. Provisional Application Ser. No. 61/844,532, filed Jul. 10, 2013,and U.S. Provisional Application Ser. No. 61/949,079, filed Mar. 6,2014, the contents of which are hereby incorporated by reference as ifrecited in full herein for all purposes.

BACKGROUND

The inventive subject matter disclosed herein generally relates to fiberproducts, such as nonwoven textiles and insulative materials consistingof webs of superfine fibers, i.e., fibers with diameters in nanoscale ormicron-scale ranges, for use in articles of apparel and outdoorequipment. In some embodiments, the articles have a predetermined degreeof waterproofness, windproofness and breathability. In certain aspects,the inventive subject matter is directed to production of such articlesand components of the articles, using novel processes for forming jetsor streams of materials that solidify as superfine fibers, and whichform into webs as they are collected. The inventive subject matter isalso directed to related apparatus and post-web formation processinginto end products.

There are several different methods and materials used to make apparelwaterproof and still allow moisture vapor from the internal microclimateto pass through the jacket to the outside environment. Under certainstandards used in the textile and outdoor products industries,waterproofness may be determined using American Test Standards AATCC 127and ASTM D751 (Japanese standard JISL 1092 or Fed. Std. 191-A55,respectively). Similarly, breathability may be determined using reportedusing American Test Standard ASTM E96 or Japanese Standard JISL 1099.

Waterproof barriers may be made using porous and nonporous materialswith hydrophobic or hydrophilic properties. These membranes can furtherbe separated into ones based on hydrophilic monolithic coatings(non-porous continuous films), or ones based on hydrophobic andmicroporous films (continuous films that incorporate microporous holesto allow moisture vapor to pass through). These films can be coateddirectly onto a fabric and then cured with high heat. The compositestructure provides waterproof and breathable protection. In other cases,the films can also be placed directly on transfer paper and thenlaminated (by gluing, for example) directly onto the fabric of choice,creating a waterproof, breathable fabric. The lamination method providesbetter durability for the film and often allows the film to be thinner,which increases breathability.

Breathability is directly related to the material properties, film type,and thickness of a barrier film. For the case of hydrophilic films, thebreathability is a diffusive process governed by Fick's Law ofdiffusion. Water is absorbed from the surface into the film, diffusesthrough the film, and evaporates on the outside. Vaporized water cannotpenetrate this film under conditions of intended use. For the case ofmicroporous films, breathability is a mechanical process where vaporizedwater must navigate between the microporous structure of the film andevaporate on the outside to the environment. Liquid water cannotpenetrate this film because of the hydrophobic properties of themembrane. A balance of pore size, thickness, and durability is necessaryto reach any performance specifications for waterproof, breathablematerials. Taking garments as representative end products, neithervaporized water nor liquid water, can penetrate into a garment from theexternal environment because of the temperature and humidity gradients.These gradients are created between the inside microclimate of thegarment and the outside environment. Because the temperature andhumidity on the inside of the garment is higher, the moisture is forcedout of the internal microclimate and into the outside environment,passing through the waterproof barrier.

A well-known and highly successful waterproof, breathable membrane,GORE-TEX, expanded polytetraflouroethylene (ePTFE), was created in 1969.To create expanded PTFE, the PTFE is stretched, creating many tinymicroscopic holes. These tiny holes are large enough to allow moisturevapor to pass through. However, the holes are smaller than the diameterof water in the liquid phase. Because the porosity is smaller than watermolecules, water in the liquid phase cannot pass through the membrane.PTFE, because it is fluorinated, has a very high surface energy, whichcauses the surface to be very hydrophobic. Combining the pore structurewith the hyrdophobicity of the surface allows the membrane to becompletely waterproof and still breathable, under conditions of intendeduse.

FIGS. 1A-1D show scanning electron microscope images of certainwaterproof breathable micro-porous membranes used in waterproof,breathable laminates, each image including pertinent descriptiveinformation on the nature of the material. (Credit: Gibson et al,“Moisture Transport for Reaction Enhancement in Fabrics”, Volume 2013,Article ID 216293, 8 pages, 29 Jan. 2013, Hindawi PublishingCorporation, http://dx.doi.org/10.1155/2013/216293.)

Following the invention of GORE-TEX ePTFE films, many competitivemembranes have been created using an array of materials that are eithercoated directly onto a fabric or laminated onto fabric. These includemembranes based on hydrophilic polyurethanes, hydrophobic polyurethanes,PTFE, and polyesters.

Electrospinning is a technique that has been used extensively in themedical and filtration industries to create nonwoven webs or mats froman accumulation of nanofibers. Many university's and industry companieshave electrospinning apparatus, patents around the process, as well asproducts. Most electrospinning has focused on nonwoven membraneproduction. The typical setup includes: a high-voltage source connectedto a syringe or needle that is coupled to a source of a fluidfiber-forming material. An electrical field is created so as to chargethe needle or syringe where the fluid exits. Electrodes for focusing,steering, and guiding the exiting solutions are positioned below theneedle or syringe. These help guide/draw the fluid into a nanofiber fromthe needle or syringe and onto the collector. Other techniques used fornonwoven mat production include: dry laying, spin melting, and wetlaying.

A process based on fiber creation requires three main productionprinciples: (1) web forming; (2) web bonding; and (3) fabric finishing.Web bonding can take place via chemical, thermal, or mechanical bonding.Chemical bonding, for example, can be a liquid-based bonding agent or awater-based binder. This bonding can be applied as a coating, which maybe printed, or impregnated on the fabric. Options for thermal bondinginclude: heat and pressure; heat and contact; or powder bonding.Mechanical bonding methods can include needle punching, stitch bonding,or hydro-entanglement.

Conventionally, nonwoven textiles can be made from many materials, butthe fibers used typically have short fiber lengths, which limits thedurability of webs made from the fibers. Also, the fiber diameters usedin conventional nonwoven textile production techniques do not reach thenanoscale level.

Nanoscale fibers can be produced from electrospinning techniques and maynot always require the strenuous bonding methods previously described.However, electrospinning has many fabrication parameters that may limitspinning certain materials. These parameters include: electrical chargeof the spinning material and the spinning material solution; solutiondelivery (often a stream of material ejected from a syringe); charge atthe jet; electrical discharge of the fibrous membrane at the collector;external forces from the electrical field on the spinning jet; densityof expelled jet; and voltage of the electrodes and geometry of thecollector.

Electrospun nanofibers have high surface area and small fiber diameter.They can be formed into webs that have air permeability, and the webscan increase in thickness, if necessary, without losing breathability.They are also lightweight.

Electrospinning technology has been gaining success in the outdoorindustry. Among recent electrospun products is the high volumeproduction of Polartec's NEOSHELL materials. The benefits of anelectrospun membrane are similar to the benefits from GORE-TEX andmicroporous membranes.

During the electrospinning process the nanofibers are collected on acollector. As the nanofibers are collected, tiny pores between thecrossing fibers develop. These tiny spaces allow for betterbreathability than a solid hydrophilic membrane or even a hydrophobic,microporous membrane. Because the nanofiber membrane has tiny pores,contamination of these pores is possible. Similar to PTFE fabrications,a micrometer thin polymer coating may be placed over the nanofibermembrane to protect the pores from contamination of dirt and oil,without affecting the breathability. Additionally, because nanofibermats are porous, they can be used for regulation of air permeability infabrics (e.g., in fabrics used in softshell garments).

Softshell fabrics are not intended to be waterproof because seams arenot taped. The protective coating is not always necessary because themembrane is sandwiched between two fabrics to protect the membrane fromcontamination. Therefore, the air permeability through the nanofibermembrane is un-impeded. NEOSHELL (Polartec) material is an example ofthis softshell application. Softshells can be 100% windproof or meteredanywhere below 100% blockage. In other wind-blocking applications, thegarment includes a lamination of a waterproof membrane between twosoftshell materials or the application of a dot glue matrix structurefor partial wind blocking. While electrospun membranes can be areplacement for waterproof, breathable membranes and wind-meteredsoftshells, the drawback of electrospun membranes is their durability.Hence, their use in two-layer (2L) constructions has not been availablebecause this.

In summary, current methods of production are resource intensive:requiring multiple processing steps, water, heat, and electricity, andin the case of electrospinning high voltage (can be dangerous). Due tothe processing parameters of electrospinning, materials for membranesare also limited to a relatively narrow range. Consequently, the end usepossibilities are also limited. Further, existing membranes may lackdurability, limiting their use in end products.

In view of the foregoing disadvantages in the prior art, there is asubstantial need for improved nonwoven textile products that are basedon superfine fibers such as nanofibers.

SUMMARY

The inventive subject matter disclosed herein overcomes the foregoingand other disadvantages in the prior art. In certain aspects, theinventive subject matter is directed to production of such articles andcomponents of the articles, using novel processes for forming jets orstreams of materials that solidify as superfine fibers, and which forminto two- or three-dimensional webs as they are collected. The webs maybe in the nature of films, membranes, or mats. In some embodiments, theinventive subject matter generally relates to nonwoven textilesconsisting of webs of superfine fibers, i.e., fibers with diameters innanoscale or micronscale ranges, for use in articles that have apredetermined degree of waterproofness, windproofness and breathability.

The inventive subject matter is also directed to related apparatus andpost-web formation processing into end products.

In other embodiments, the inventive subject matter is directed toinsulating materials made of fiber webs of fibers or agglomerations offibers. The insulating materials may be used in a variety ofapplications, including garments and apparel, sleeping bags, blankets,upholstery filling, etc.

The inventive subject is also directed to systems and methods forcollecting fibers of any scale in agglomerations of generally parallelstrands for use in forming yarns, for example. In addition, fiber matscan be cut into different widths and the yarns spun from the twistingpulling of fibers from the mats

These and other embodiments are described in more detail in thefollowing detailed descriptions and the Figures.

The foregoing is not intended to be an exhaustive list of embodimentsand features of the inventive subject matter. Persons skilled in the artare capable of appreciating other embodiments and features from thefollowing detailed description in conjunction with the drawings. Theappended claims, as originally filed in this document, or assubsequently amended, are hereby incorporated into this Summary sectionas if written directly in.

BRIEF DESCRIPTION OF THE DRAWINGS

The following Figures show embodiments according to the inventivesubject matter, unless noted as showing prior art.

FIGS. 1A-1D show scanning electronic microscope images and associatedmicroscopy and materials details for several known microporousmembranes.

FIG. 2 schematically illustrates a composite construct that may includea layer of waterproof-breathable material produced according to theinventive subject matter.

FIG. 3 schematically illustrates a force spinning system for use inproducing constructs according to the inventive subject matter.

FIGS. 4A-B schematically illustrate the use of a mold in connection witha force spinning system.

FIG. 5 schematically illustrates a down plumule, such as from a goose orduck

FIG. 6 is a schematic comparison of conventional batting (left side) andbatting (right side) according to the inventive subject matter.

FIG. 7 schematically illustrates a force spinning system for use inproducing synthetic down constructs according to the inventive subjectmatter.

FIG. 8 schematically illustrates an alternative embodiment of a forcespinning system for use in producing synthetic down constructs accordingto the inventive subject matter.

FIGS. 9A-B schematically illustrates a force spinning system for use inproducing and collecting filaments according to the inventive subjectmatter.

FIGS. 10A-C schematically illustrate alternative embodiments of a forcespinning system for use in producing and collecting filaments accordingto the inventive subject matter.

FIG. 11 schematically illustrates a further alternative embodiment of aforce spinning system for use in producing and collecting filamentsaccording to the inventive subject matter.

FIG. 12 schematically illustrates a further alternative embodiment of aforce spinning system for use in producing and collecting filamentsaccording to the inventive subject matter.

FIG. 13 schematically illustrates a further alternative embodiment of aforce spinning system for use in producing and collecting filamentsaccording to the inventive subject matter.

DETAILED DESCRIPTION

Representative embodiments according to the inventive subject matter areshown in FIGS. 2-13, wherein the same or generally similar features mayshare common reference numerals.

The inventive subject matter disclosed herein relates to compositions ofnonwoven, fibrous films or membranes based on superfine fibers for usein construction of articles that have a predetermined degree ofwaterproofness, windproofness and breathability. The inventive subjectmatter is directed in part to production of such articles and componentsof the articles, using novel processes. As used herein, superfine fibersmeans fibers having an average diameter (or other major cross-sectionaldimension in the case of non-circular fibers) in the micron scale tonanoscale. As used herein, “micron scale” means the fibers have averagediameters in the range of single-digit microns to as low as about 1000nanometers. In the textile industry, nanoscale fibers have averagediameters in the range of about 100-1000 nanometers or less). In certainembodiments, superfine fibers exhibit a high aspect ratio(length/diameter) of at least 100 or higher. Superfine fibers may beanalyzed via any means known to those of skill in the art. For example,Scanning Electron Microscopy (SEM) may be used to measure dimensions ofa given fiber.

The superfine fibers may be formed into two- or three-dimensional webs,i.e., mats, films or membranes. The fibers may be produced using forcedejection of a selected starting fiber-forming, fluid material through anoutlet port. The outlet port and associated channel feeding isconfigured with a size and shape to cause a fine jet of the fluidmaterial to form on exit from the outlet port. As used herein, an outletport means an exit orifice plus any associated channel or passagefeeding the outlet port and serving to define the nature of the expelledjet of fiber-forming material. Due to factors such as surface tension,fluid viscosity, solvent volatility, rotational speed, and others, theejected material can solidify as a superfine fiber that has a diametersignificantly less than the inner diameter of the outlet port. Herein,such expulsion of flowable material from an outlet port as a jet thatsolidifies as a fiber may be referred to as “jet extrusion”.

The jet of expelled material is directed to a collector, where it isgathered for use in an end product. The collected fiber material forms aweb of two- or three-dimensional entangled fibers that can be worked toa desired surface area and thickness, depending on the amount of timefibers continue to be expelled onto a collector, and control over thesurface area of the collector (e.g., a moving belt as a collector canallow for sheets of material of unlimited length). Other properties,such as web density and porosity will depend on such factors as thenature of the fibers, processing temperatures, speed and path of jets,etc. The working of the web to a desired thickness, surface area,density, and/or porosity may also include post-processing steps, such ascompression of the collected webs, thermal processing for densificationor expansion (depending on nature of fibers), chemical processing, andprocessing with electromagnetic radiation (e.g., UV wavelengths toinduce cross-linking).

In certain embodiments a rotary device imparts centrifugal force on afiber-forming material to cause jet extrusion and consequently fiberformation. The force that is imparted on the source material may comefrom various systems and techniques that do not require appliedelectrical fields, as in electrospinning. For example, U.S. Pat. Nos.4,937,020, 5,114,631, 6,824,372, 7,655,175, 7,857,608, 8,231,378,8,425,810, and US Publication No. 20120135448, teach various devices andprocesses for forced ejection of fiber-forming material through anoutlet port on a rotary device. The foregoing collection of patentdocuments includes disclosures for systems for production of fibers withaverage diameters in the micron-scale or nanoscale range. The foregoingpatent documents are hereby incorporated in their entireties for allpurposes. An alternative approach to rotary systems is based onnon-rotary pressure feeding of a fiber-forming fluid through an outletport that creates a jet of the fluid that forms into a fiber. Forexample, U.S. Pat. No. 6,824,372, which is hereby incorporated byreference in its entirety for all purposes, discloses a chamber thatimparts ejection force on a fiber-forming fluid contained therein viaoscillating pressure changes that are generated by a movable wall forthe chamber.

It is notable that none of the foregoing patent documents teach theproduction of waterproof, breathable materials and products made fromthe disclosed apparatuses or processes.

The inventive subject matter is particularly directed to certainarticles incorporating superfine fibers created by jet extrusion, thearticles consisting of garments and apparel, e.g., jackets and pants;footwear, e.g., shoes and socks; headwear, e.g., soft caps and brimmedor visored hats, and facemasks; outdoor equipment, e.g., sleeping bagsand shells for sleeping bags, blankets, tents, tarps and other covers;and luggage and packs, e.g., soft-sided bags, backpacks, waist packs,suitcases, duffel bags, bike messenger bags and other bags for bikers,briefcases, etc.

FIG. 2 shows an example of a possible assembly of layers used to form acomposite structure 1 for use in end products, such as those mentionedabove. The assembly includes an upper first layer 2 that is positionedabove a second or intermediate layer 3. The intermediate layer ispositioned above a third lower layer 4. In any of the layers, the layermay be a continuous layer of material or a discontinuous layer. Indiscontinuous layers, the layers can be characterized as interconnectedmaterials with voids, openings, channels, etc., or they can becharacterized as disconnected materials, such as an array of dots. Forexample, the lower layer 3 in FIG. 2 is seen as an interconnected web ofmaterial with square-shaped voids. That layer may represent a discretesheet of such material or a pattern applied by a deposition techniquesuch as screen printing.

In some waterproof-breathable applications for outerwear known as “3L”construction or composite, the first layer 2 is an outer layer thatconsists of a hard shell material. Example materials include nylon,polyester, and wool. Layer 2 or other layers may be a woven fabric, anonwoven fabric, or a knit fabric. Layer 3 is a microporous membranemade of PTFE or polyurethane, for example. Layer 4 is a liner layer madeof a textile formed of synthetic or natural fibers, or blends. Examplematerials include nylon, polyester, and wool. Layer 4 may be a wovenfabric, a nonwoven fabric, or a knit fabric. In this example, themicroporous membrane is a waterproof, breathable membrane that allowswater vapor 5 to pass through but blocks liquid phase water 6.

As indicated above, layer 3 may be created using any forcespinning orother jet extrusion technique described herein. Layers 3 or 4 may be asubstrate onto which the layer 3 material is collected during suchtechnique. A third layer may be added in an inline process.

Where layer 3 in a three-layer construction is a discontinuous layer ora thinly deposited film layer, e.g., a screen-printed layer, theassembly may be referred to as a “2.5L” composite. If the composite isbased on just a laminated construction of the intermediate layer 3 andan outer or inner layer, the construction may be referred to as a “2L”composite. It should be understood that the foregoing forms of compositeconstructions are typical for outerwear. However, any number of otherlayers may be included in a composite assembly.

The layers in a composite assembly may be bound together using any ofvarious known or to be discovered means, including known means such asthermal (fusion) bonding, ultrasonic welding, chemical bonding (directbonding of layer material to layer material, or through intermediateadhesives), and stitching and other forms of mechanical fastening.

In certain embodiments, a micro-porous membrane is formed directly on asubstrate that is a component of an end product, e.g., a layer ofmaterial for a jacket or a glove.

In certain embodiments, the substrate onto which fibers are collected isa volumetric mold (positive or negative), i.e., a substrate that impartsa desired three-dimensional shape for use as or in an end product or acomponent thereof. The mold may comprise or include other components ofthe end product. The fibers may be collected on the other componentsassociated with the mold. Or, they may be substantially isolated fromother components.

For example, the mold may be a last 7 or other form for a shoe 8. (FIGS.4A-4B.) The mold onto which fibers are collected may be bare or it mayhave a layer of a material that represents an inner liner of a shoe,which becomes bonded or otherwise assembled to the overlaid fibernetwork. The last may have a sole unit, e.g., an outsole, midsole,and/or sockliner, associated with a bottom surface of the last, whichbottom surface is oriented on the surface of tray or other support suchthat the sole unit is generally isolated from and does not collectfibers. However, in some applications, a portion of a sole unit may beintended for collection of fibers. For example, a peripheral edge may beexposed to fibers, allowing fibers to collect for direct bonding to theexposed edge to form an integral assembly of the sole unit with theupper for the shoe. The mold may be static or rotated during thecollection process.

In other examples, the mold may be configured as a garment or item ofapparel, for instance, a jacket shell, pants, or part thereof, e.g. asleeve or pant leg; a hat; an item of outdoor equipment. FIG. 5 shows amold or form for a glove in a force-spinning system. From the foregoing,it can be understood that the inventive subject matter allows for theformation of membranes or films composed of superfine fibers that have athree-dimensional configuration and seamlessness over the moldedconfiguration. In some but not necessarily all embodiments, superfinefibers, including ones at the nanoscale, are formed into a 3D membraneor film that is a waterproof, windproof, and/or breathable layeraccording to outerwear industry standards.

As indicated above, use of rotary forces to eject a flowable,fiber-forming material as a jet or stream from an outlet port isparticularly suitable for use in the inventive subject matter. Such atechnique may be referred to hereinafter as “forcespinning”.

In contrast to the prior art, forcespinning uses a small amount ofelectricity, and produces much longer fibers (up to 1 meter or more).Longer fibers allow for stronger and more durable webs. Forcespinningalso allows for a highly consistent and controlled deposition ofnanofibers of the same diameter, and it may not require any water, andmay not involve generation of toxic chemical vapors. The force-spinningprocess has relatively very little waste. It is also adaptable for usewith a wide range of fiber-forming materials.

Webforming/Forcespinning Process Overview:

The processes and equipment for forcespinning are known to personsskilled in the art by virtue of various known teachings, such as some ofthe patent documents listed above, as well by virtue of commercialequipment suppliers such as FibeRio Technology Corporation, McAllen,Tex., USA, which supplies a line of forcespinning equipment (Seehttp://fiberiotech.com/products/forcespinning-products/). Therefore, adetailed description of forcespinning is unnecessary, and only is abrief description will be provided herein.

Forcespinning is a process to extrude super fine fibers usingcentrifugal force to elongate the fibers. This creates cohesive,nonwoven mats of fiber networks. Fiber crossings generate contactpoints. This creates inter-fiber porosity, and, in the case ofrelatively long fibers, intra-fiber porosity, as well. Fiber contactsand fiber morphology influence the size of the pores. Because of thenetwork structure, these pores exist in multiple planes (vertically,horizontally, and diagonally).

In electrospinning, the surface area of electrospun membranes increaseswith increased fiber diameter. In electrospun membranes, pore sizes assmall of 500 nm have been recorded. Water vapor molecules areapproximately 0.4 nm, and water molecules (liquid) are approximately500,000 nm. This allows vapor to pass through electrospun membranes butnot water in the liquid form. The same fiber diameters and porosity isattainable with forcespinning techniques. Therefore, this similarityprovides large diversity to fiber morphologies and fiber diameters thatcan be adapted from electrospinning, but avoiding the disadvantages orelectrospinning technologies. Furthermore, forcespinning is believedcapable of creating fibers that can be three or more times the length ofcorresponding electrospun fibers. This difference allows for moredurability in finished articles.

Referring to FIGS. 3-4, a force-spinning system 10 is shown forproducing superfine fibers and collecting them into a cohesive web, suchas a film or mat. The system includes a spinneret 12 that is fluidlycoupled to a source of fluid or flowable material that is formable intoa fiber (‘fiber-forming material’). The source of material may be areservoir 14 for continuously feeding the spinneret. The spinneret coulditself include a reservoir of material that is rotated with thespinneret.

The flowable material could be molten material or a solution ofmaterial. The spinneret is mechanically coupled to a motor (not shown)that rotates the spinneret in a circular motion. In certain embodiments,the rotating element is rotated within a range of about 500 to about100,000 RPM. In certain embodiments, the rotation during which materialis ejected is at least 5,000 RPM. In other embodiments, it is at least10,000 RPM. In other embodiments, it is at least 25,000 RPM. In otherembodiments, it is at least 50,000 RPM. During rotation, a selectedmaterial, for example a polymer melt or polymer solution, is ejected asa jet of material 15 from one or more outlet ports 16 on the spinneretinto the surrounding atmosphere. The outward radial centrifugal forcestretches the polymer jet as it is projected away from the outlet port,and the jet travels in a curled trajectory due to rotation-dependentinertia. Stretching of the extruded polymer jet is believed to beimportant in reducing jet diameter over the distance from the nozzle toa collector. The ejected material is expected to solidify into asuperfine fiber by the time it reaches a collector. The system includesa collector 18 for collecting the fiber in a desired manner. Forexample, the fibers could be ejected from the spinneret onto a surfacedisposed below the spinneret or on a wall across from outlet ports onthe spinneret. The collecting surface could be static or movable. Toform a sheet or mat 20 of fibrous material, the surface could be a flatsurface. The flat surface could be static or movable.

A movable flat surface could be part of a continuous belt system thatfeeds the fibrous material into rolls or into other processing systems.Another processing system could be an in-line lamination or materialdeposition system for laminating or depositing other materials ontosheet material produced using the force-spinning system or other systemfor producing sheeted material of superfine fibers. In otherembodiments, the flat surface could support a layer of another materialonto which the fibers are deposited. For example, the layer of materialsonto which fibers are deposited could be an inner or outer layer for acomposite assembly of layers for an end product, such as an item ofapparel.

In certain embodiments, the collecting surface is a 3D object such as amold or 3D component of an end product. FIGS. 4A-4B show examples of 3Dobjects 7,8 for end products that are shoes or gloves. FIG. 5 shows a 3Dobject in the form of a down plumule, which may be imitated, asdiscussed in more detail below.

To direct fibers to a desired collecting surface (a “collector”), afiber-directing system may be made a part of the force-spinning system.For example, the directional system may be configured to provide airfrom above and/or vacuum from below the desired collector to direct thefibers to the collector. (See FIGS. 3-7.)

As the superfine fibers are laid upon each other, contact points aremade at intersections, and the membrane constituents bind together. Ifany web-bonding of the contact points is desired, it may be accomplishedvia application of heat (thermal bonding), heat and pressure, and/orchemical bonding. The force-spinning system may include heatingelements, pressure applicators, and chemical bonding units for achievingsuch bonding.

Under the inventive subject matter, forcespinning may be further appliedto the deposition of multiple layers of fibers using combinations ofspinneret orifice sizes, orifice geometries, and configurations. Forexample, fibers can be made into circles, uncollapsed circle (i.e.,basically a circular fiber, hollow in the center, that is compressedinto an ellipse), or flat ribbons.

Additionally, different spinnerets can be included in a force-spinningsystem, resulting in different fiber diameters or blends. For example,multiple spinnerets in a system can create fiber blends during thespinning. Spinnerets can also be configured with outlet ports that cancreate a core-sheath structure. Alternatively, a single spinneret withmultiple outlet ports, each coupled to a reservoir of a differentflowable, fiber-forming material can create blends.

Similarly, fiber properties can be controlled by providing on the rotarydevice different outlet ports of varying selected diameters. Theinventive subject matter contemplates a range of outlet port diametersfrom between about 1 to about 1000 micrometers. Larger diameters arealso contemplated if relatively high diameter fibers are desired.Channels or passages leading to outlet ports typically would havestraight runs. They may be as long as 1-3 millimeters.

In a given system, the diameters and/or shapes or dimensions of theoutlet ports may be uniform or they may be varied. In some embodiments,the outlet ports are formed as nozzles of a predetermined length thathave decreasing taper toward the port. Outlet ports and associatedpassages or channels may be formed using known micromilling techniques,or to be discovered techniques. Known techniques include mechanicalmillings, chemical etching, and laser drilling and ablation.

In addition to superfine fibers, forcespinning systems according to theinventive subject matter may be used to create fibers of standardtextile size (e.g., 50-150 denier).

These superfine or other fibers may include functional particles suchas, but not limited to, antimicrobials, metals, flame-retardants, andceramics. These materials may be introduced into the spinneret alongwith the fiber-forming material. They may bond to the materialcovalently, by hydrogen bonds, ionic bonds or van der Waals forces, forexample. A catalyst may be included in the material mixture tofacilitate any such bonding.

In any case, for the above-mentioned end products, the fiber mats(ranging from different fiber sizes, materials, or blends) can belayered together to create whole garment composites, or in the case of3D objects, whole end products, e.g., shoe composites and gloves. Thecollected fibers can be carded for spinning into yarn. The yarn may beused in, for example, apparel, footwear, and equipment end products, totake advantage of the unique properties that may be exhibited bynanoscale fibers. The fiber-forming materials can be chosen by melttemperatures to provide different structural rigidity in the final endproduct when heat cured after forcespinning. This may be especiallyimportant for 3D structures such as gloves and shoe uppers, whichrequire relatively more durability than other end products, such asouterwear.

The inventive subject matter contemplates use of forcespinning to createnanofiber membranes for use in 2L, 2.5L, and 3L waterproof/breathableproducts. After membranes are spun, they may, or may not, be coated witha protective film to protect the pores from contamination. Depending onmembrane end use, the fibers may optionally be extruded with anoleophobic component to protect the membrane from contamination of dirtand oils, or a similar oleophobic coating can be applied after themembrane is spun. Coating with an oleophobic coating will not cover thepores in the membrane or adversely affect the breathability or airpermeability, but will still modify the nanofiber surface as to notattract dirt and oil and hence prevent contamination.

The membranes may be directly spun onto the chosen face fabric of thefinal material, or the membranes may be spun onto contact paper and thenlaminated onto the chosen face fabric of the final material. Themembrane, either deposited directly on the fabric, or material, orlaminated on the material, may also be used in softshell constructions.The diameter of the nanofiber affects pore size of the membrane. Thecross-sectional morphology of the fibers and fiber thickness affect thesurface area of the fibers. Increasing the surface area of the fiberscan reduce the pore size. Reducing the fiber diameter is a way toincrease surface area/volume ratio. Therefore, fiber diameter is a wayto control thickness, durability, and moisture vapor transfer. Thicknessaffects weight of the membrane. Collectively, these factors influencethe breathability and durability of the nanofiber membrane. Nanofiberdiameters according to the inventive subject matter can be anywhere inthe nanoscale range. A suitable range for applications described hereinis believed to be about 100 nm to about 1000 nm. Pore size influencesair permeability. Therefore, the air permeability for a membrane may becontrolled for most applications using nanofibers in the foregoing sizerange. Fiber-forming materials of use for softshell and waterproofbreathable applications include PFTE dispersions, polyurethanes, nylons,polyesters, bio-based materials, e.g., such cellulosic materials, silkproteins, and other fiber-forming materials that are to be discovered,including other polymers derived from natural and synthetic sources.

In certain embodiments of the inventive subject matter, the flowable,fiber-forming material may be a mixture of two or more polymers and/ortwo or more copolymers. In other embodiments, the fiber-forming materialpolymers may be a mixture of one or more polymers and or morecopolymers. In other embodiments, the fiber-forming material may be amixture of one or more synthetic polymers and one or more naturallyoccurring polymers.

In some embodiments according to the inventive subject matter, thefiber-forming material is fed into a reservoir as a polymer solution,i.e., a polymer dissolved in an appropriate solution. In thisembodiment, the methods may further comprise dissolving the polymer in asolvent prior to feeding the polymer into the reservoir. In otherembodiments, the polymer is fed into the reservoir as a polymer melt. Insuch embodiment, the reservoir is heated at a temperature suitable formelting the polymer, e.g., is heated at a temperature of about 100° C.to about 300° C.

In some embodiments according to the inventive subject matter, aplurality of micron, submicron or nanometer dimension polymeric fibersare formed. The plurality of micron, submicron or nanometer dimensionpolymeric fibers may be of the same diameter or of different diameters.

In some embodiments according to the inventive subject matter, themethods of the invention result in the fabrication of micron, submicronor nanometer dimensions. For example, it is believed possible tofabricate polymeric fibers having diameters (or similar cross-sectionaldimension for non-circular shapes) of about 15, 20, 25, 30, 35, 40, 45,50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 140, 150,160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290,300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430,440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570,580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700, 710,720, 730, 740, 750, 760, 770, 780, 790, 800, 810, 820, 830, 840, 850,860, 870, 880, 890, 900, 910, 920, 930, 940, 950, 960, 970, 980, 990,1000 nanometers, or 2, 5, 10, 20, 30, 40, or about 50 micrometers. Sizesand ranges intermediate to the recited diameters are also part of theinventive subject matter.

The polymeric fibers formed using the methods and devices of theinvention may be of a range of lengths based on aspect ratios of atleast 100, 500, 1000, 5000 or higher relative to the foregoing fiberdiameters. In one embodiment, the length of the polymeric fibers isdependent at least in part, on the length of time the device is rotatedor oscillated and/or the amount of polymer fed into the system. Forexample, it is believed that the polymeric fibers may be formed havinglengths of at least 0.5 micrometer, including lengths in the range ofabout 0.5 micrometers to 10 meters, or more. Additionally, the polymericfibers may be cut to a desired length using any suitable instrument.Sizes and ranges intermediate to the recited lengths are also part ofthe inventive subject matter.

As used herein, the terms “fiber” and “filaments” may be usedinterchangeably, with the term “filament” generally referring to acategory of “fiber” of high aspect ratio, e.g., a fiber of relativelylong or continuous lengths that can be spooled around a desired object.Further, synthetic fibers are generally produced as long, continuousfilaments. In contrast, “staple fibers” usually refers to naturalfibers, which tend to be relatively short because that is how they aretypically grown. Long synthetic filaments can be chopped into shortstaple fibers. In summation, a filament is a fiber, but a fiber can bein different lengths (staple or long or continuous).

In some embodiments, the polymeric fibers formed according to themethods of the inventive subject matter are further contacted with orexposed to an agent to reduce or increase the size of pores, or thenumber of pores, per surface unit area in the polymeric fibers. Forexample, various known chemical agents may be used, which are known toincrease or decrease cross-linking in polymers or denature non-covalentlinkages. Non-chemical agents may include heat and electromagneticradiation.

The inventive subject matter is particularly suited for producingend-products having waterproof and breathable protection, as well aswind protection. Other nanofiber webs for waterproof and moisturebreathability have been produced via electrospinning. Similar dimensionsare believed possible by jet extrusion, but with greater fiber lengthsthan possible via electrospinning. The dimensions of these are 1000 nmor less. The webs are expected to have a range of fabric weights andweigh about 5 to about 25 g/m², with a thickness of about 10 to about 50micrometers (See, e.g., Korean Patent Document No. 20090129063 A). Forforcespun microporous membranes for waterproof/breathable applications,PTFE is an example of a suitable fiber-forming material. Suitable PTFEfiber diameters may range from about 100 nm to about 1000 nm. A range ofthicknesses of webs is possible. A suitable thickness of the membranethickness may be from about 7 micrometers to about 50 micrometers. Arange of pore sizes in webs is possible. Suitable pore sizes forwaterproof/breathable applications include about 250 nm or greater.

A wide variety of materials (synthetic, natural, bio-based-plants,bio-based-fermented) and fabric/substrate types (knits, wovens, andnonwovens) are contemplated for use in end products. Non-limitingexamples of superfine fibers that may be created using methods andapparatuses as discussed herein include natural and synthetic polymers,polymer blends, and other fiber-forming materials. Polymers and otherfiber-forming materials may include biomaterials (e.g., biodegradableand bioreabsorbable materials, plant-based biopolymers, bio-basedfermented polymers), metals, metallic alloys, ceramics, composites andcarbon superfine fibers. Non-limiting examples of specific superfinefibers made using methods and apparatuses as discussed herein includepolytetrafluoroethlyene (PTFE) polypropylene (PP), polyurethanes (PU),Polylactic acid (PLA), nylon, bismuth, and beta-lactam superfine fibers.

Superfine fiber collections may include a blending of multiplematerials, as indicated above. Superfine fibers may also include holes(e.g., lumen or multi-lumen) or pores. Multi-lumen superfine fibers maybe achieved by designing, for example, one or more outlet ports withconcentric openings. In certain embodiments, such openings may comprisesplit openings (i.e., an opening that possesses one or more dividerssuch that two or more smaller openings are made). Such features may beutilized to attain specific physical properties. For instance, thefibers may be produced for use as thermal insulation, such as in theinsulation applications described below, or for use as elastic(resilience) or inelastic force attenuators.

In certain embodiments, fibrous webs of the present disclosure mayinclude elastic fibers, such as elastane, polyurethane, and polyacrylatebased polymers, to impart stretchability to the nonwoven textiles madeaccording to the inventive subject matter.

In some embodiments, the inventive subject matter is directed to fibers,and constructs of thermally insulative fibers that are producedaccording to the jet extrusion techniques disclosed herein. In somepossible embodiments, the constructs may be made in a form similar tonatural down, which is an agglomeration of plumules. FIG. 5 is aschematic of a single down plumule 22. The plumule has a central nodewith a plurality of arms radiating outwardly from the node. Such astructure allows for a high degree of air entrapement relative to linearfiber having a length similar to the diameter of the plumule.

The insulative constructs according to the inventive subject matter mayalso be in a form similar to synthetic batting insulation, such as thosemarketed under such names as Primaloft, Thermore, or Thermolite.Typically, such products are based on polyester fibers or blends ofpolyester and other natural or synthetic fibers, such as fibers ofMerino wool. FIG. 6 is a schematic representation of how such aconstruct 20 would appear relative to known products 21, i.e., they maybe constructed in a matt-like form based on entanglement oragglomeration of linear fibers. Typically, such bats are produced bymelt blowing of fibers. In contrast to the prior art, superfine fibersaccording to the jet extrusion teachings herein may be used to achieveimproved performance based on the superfine fiber diameters and/or useof nanotobes or other structures that increase volume of entrapped airper a given unit of density of insulative material. The superfine fibersmay be blended with larger diameter fibers that provide strength ordurability to the blended construct of fibers.

The fibers in a construct of insulative materials may be ofsubstantially the same deniers or they may be a blend of deniers. Ineither case, a suitable range for many applications is 1-5 deniers. Inapparel applications, a suitable range may be 1-3 deniers.

Node-like structures can be made that mimic the 3D structures of goosedown plumules, for example. In general, a unit of fiber structure thathas a high degree of crossing fibers simulates a node at each crossoverpoint. Accordingly, the inventive subject matter contemplates formingstructures with a high degree of cross overs per a given unit ofdensity, and many loose and relatively small web structures that canagglomerate with the loftiness of down plumules. In other words, thesynthetic down insulative structures are not extended sheets or mats ofmaterial but instead entangled or intersecting webs of micro-sized unitsthat provide fill and loft comparable to or better than down. FIG. 7schematically illustrates one possible method of creating a high degreeof cross over and many loose structures. In this example, the jetexpulsion system is a forcespinning system 10. The system includes acollector 118 associated with variable or multidirectional air flow thatcreates a vortex or turbulence (airflow indicated by up/down arrowsthrough a collector surface in FIG. 7). The vortex or turbulence causesthe fibers or fiber segments coming off the spinneret to encounter eachother in random or otherwise intersecting paths in a relatively confinedspace. This causes a high degree of fiber cross over and short sectionsof webs. The spinneret may issue the jets from the associated outletports in pulses to facilitate the formation of discrete balls ofentangled fibers. Other means for causing such an effect may includecontrolling the tensile forces on the jetted fibers or selecting fibermaterials of desired tensile strength such that the webs of fiber breakapart before growing undesirably large, creating many packets of small,loose webs. In other embodiments, mats or sheets of insulating materialmay be cut into tiny sections, using known techniques such asmechanical, chemical or electromagnetic cutting mechanisms.

FIG. 8 shows an alternative system for creating insulative constructsthat mimic down. In this system, the collector is in the nature of arotating vessel 218. The jetted fibers frictionally interact with therotating vessel causing the fibers to decelerate and entangle with eachother. The forces are such that large continuous mats of material do notform, just loose, tiny webs of material. The vessel may also be coupledwith a variable airflow mechanism similar to cause crossover of fibers,as described above.

Using the superfine fibers and techniques according to the inventivesubject matter, it is expected that constructs of insulative materialcan be achieved that will have a fill power equivalent of at least about450 to about 1,000. It is also contemplated that some insulativeconstructs may have a fill power equivalent of over 450, or over 550, orover 650, or over 750, or over 850, or at least 1,000. Sizes and rangesintermediate to the recited fill equivalents are also part of theinventive subject matter.

Additionally, insulative constructs made using nanofibers can createadditional air space relative to prior art insulative materials. Theadditional air space results in better insulating properties and hencewarmer-feeling garments, for example. For instance, nanotubes and otherfiber geometries that have increased surface area, relative to asolid-core, round fiber of the same weight and length, will allow forgreater air entrapment and higher insulative values.

Making Filaments and Yarns in Long or Continuous Runs:

After fibers are created, fibers are made into yarns. For syntheticfibers there are two types of yarns: filament yarns and spun yarns.Filaments yarns are composed of many lengthy fibers agglomeratedtogether and typically oriented with longitudinal axes in parallel witheach other. A filament is a single continuous fiber that has beenextruded. Filaments can be grouped or agglomerated together with theindividual fibers in a generally parallel orientation. The bundle ofgrouped fibers is then twisted to create a thicker and stronger yarn.Fabrics use both multi-filament yarns and single monofilaments.

Synthetic spun yarns are produced using staple fibers. Staple fibers areshort fibers of about 0.75 to 18 inches long. Excluding silk, naturalfibers are staple fibers. To create synthetic staple fibers, the fiberis extruded, drawn and tensioned or crimped, and then cut to the staplefiber length. These staples are then bailed for downstream processinginto woven, knit, or nonwoven fabrics. Staple fibers are then combinedtogether and spun to create yarn made up of thousands of shortfilaments. These spun yarns are produced in much the same way as cottonor wool yarn is produced.

Carding is the mechanical process that disentangles, cleans, and orientsfibers into a continuous web that is used to spin yarn. The processbreaks up clumps of unorganized fibers and aligns the fibers of similarlengths. Natural fibers, such as wool and cotton, are often in clumps ofentangled fibers of different fiber lengths. These clumps are carded andcombed into parallel, aligned staple fibers of similar length. Thesestaple fibers are then spun into yarn that is used in woven and knittedfabrics.

In the case of cotton bundles, the basic carding process includes:opening the tufts into individual fibers, removing impurities, selectingfibers on the basis of length (removing the shortest ones), removingnaps, orienting the fiber in a parallel fashion and stretching thefiber, transforming the lap into a sliver, resulting in a regular massof untwisted fiber. A sliver is the long bundle of created fiber that isused to spin yarn.

Forcespun Staple Fibers:

As disclosed above, forcespinning can create long nanofibers. These longfibers can be cut and carded as staple fibers. It is possible to changethe size of the spinnerets, increasing or decreasing the orificediameters, to draw long, fibers of larger diameter size. For example,deniers ranging from 1 to 300 denier or thereabout are contemplated fromforcespinning methods. A given spinneret may have one or more orificesthat are all of the same size. Or, it may have a plurality of orificesof different diameters or configurations for a plurality of fiberdeniers or configurations.

Fiber mats consisting of fibers in the 1D-300D range can act similarlyto that of bundles of natural fibers like cotton and wool. It isbelieved that using the novel systems disclosed and contemplated herein,loosely packed mats or battings, of long, continuous force spun fiberscan be processed into staple fibers using the same processes used fornatural fiber. Wool, cotton, jute, etc., may use different mechanismsfor combing and carding machines. Therefore, there are many optionsavailable to separate the forcespun mats into desired lengths of staplefibers.

Creating staple fibers from forcespinning advantageously uses littleenergy. Long continuous filaments are agglomerated in generally parallelorientation, and they can easily be cut and carded to produce uniformstaple fibers. Conventional processes are limited by fiber size. Inaddition, forcespinning provides the ability to create fibers from avariety of raw materials, as disclosed herein. In contrast, conventionalprocesses have a limited ability to efficiently produce a variety ofnatural, synthetic, and bio-based fibers. For example, polyester can beextruded in long continuous filaments (like fishing line). Thesefilaments can be used as is, or cut into staple fibers. Forforcespinning, the fibers are relatively long, compared toelectrospinning, and the mats can then be cut and carded like staplefibers. The fiber mats are representative of cotton bundles ofunoriented staple fibers. However, it is contemplated that as theorifice sizes on the spinnerets increase to fiber deniers of 50 andabove, the strength of the fiber increases. Because of this, the lengthof the extruded fibers can increase. It is contemplated that theparameters, such as rotating speed, orifice size, and solution melt canbe adapted for a desired result without undue experimentation. In anycase, i.e., forcespinning of nanofibers to large denier fibers, thecarding and cutting into staple fibers would follow similar approaches.

Forcespinning Continuous Filament Fibers:

From the nanoscale to larger diameters, the inventive subject matter isdirected to the production of longer more continuous filaments fromforcespun fibers. Relatively large fibers diameters of 1 denier-300denier or thereabout, as well as other deniers or diameters disclosedherein. Filament tensile strength is increased as fiber diametersincrease.

Over traditional extrusion processes, the approaches disclosed hereinadvantageously reduce the amount of heated drums and tension devicesrequired to draw and orient the fiber because the forcespinningnaturally orients the fibers. Traditional drawing and orienting offibers, and extrusion, can require space of up to 3 stories of height.Forcespinning is a single apparatus of small dimension, quiet, andrequires little energy. In the case of some fibers, the requirement maybe to include heaters and tensioning devices. This is also envisioned,and can be included at points between the collector and spinneret or inpost processing. However, post processing is envisioned at smaller scalethan requirements of current manufacturing. Similar to nanofiber mats,larger forcespun mats can be twisted into yarns directly from the mats.This twisting causes entanglements similar to that yarns from staplefibers. If a higher degree of fiber orientation is desired the mats canbe carded as previously described.

Because of the strength of forcespun fibers of larger diameter, othermethods of collection are also envisioned.

FIGS. 9-12 show alternative embodiments of a force spinning or other jetextrusion system with a fiber collection system that collects filamentsor fibers and spool them as continuous filaments or fibers. (Systemelements are not meant for conceptual illustration and are not meant tobe at scale.) As a jet of fiber-forming material 15 exits the orifice ofa spinneret and centrifugal force draws the filament or fiber, and italigns the fiber and provides strength by orienting the polymer chainswithin the fiber. This is similar to other jet extrusion processesdisclosed herein. For example the jet may include a material selectedfrom the group of polyesters, nylons, natural fibers (e.g., cellulose),bio-based (natural derived, synthesized), blends of biocomponent fibersand fibers of unique cross-sections (core-sheath), and any othermaterial disclosed or contemplated herein. The fiber-forming materialmay include dispersed particles to increase fiber performance orconductance, for example. Any of the fiber-forming materials may becollected as continuous filaments using a myriad of collection methods.A few representative methods are outlined below. However these examplesare not meant to be an exhaustive list. Those skilled in the art willrealize from the teachings herein that many techniques and apparatusescan be employed to collect the fibers.

Forcespinning's use of a spinneret that ejects a jet or stream ofmaterial under centrifugal force offers similarities to the productionof cotton candy. As used herein, “stream” or “jet” means a fibrous orfilamentous flow of material in any state, e.g., liquid, softened, orsolid. An example of a solid stream of material would be a moving yarnbeing pulled to or from a spool. As used herein, “structure” or “strand”in the context of fibers means a solid phase fibrous or filamentousmaterial. In the processing steps contemplated herein, the structure orstrand may be present in a dynamic state, as in a streaming state, or itmay be present in a static state.

In cotton-candy makers, strands of cotton candy fiber are formed byspinning a liquid that exits from a spinneret centered in a collector.The collector in which the spinneret is centered is basically a roundbowl. The strands collect on the surrounding, vertical walls of thecollector. A spooler, which is an elongate object, e.g., a paper cone,is then moved in a circular path along the walls of the collector, withthe longitudinal axis of the spooler oriented parallel to thecollector's walls. While the spooler circles the walls, it pulls off thefiber strands deposited on the walls. While the spooler is circlingalong the walls, it is also rotated around its longitudinal axis. Thisadditional rotation winds the fibers around the spooler, to create auniform deposition of fiber strands around the spooler. In the case ofcotton candy, the fibers are weak, short, sticky, and wound withouttension. Therefore, the process is not intended for use where compactspooling of fibers is needed, or where fibers are not sticky and easilyattracted to a spooler from the walls on which they are deposited.Further, the cotton-candy maker approach offers no solution to theproblem of how to wind the mat of collected fibers into a continuousfilamentous form that is preferably, but not necessarily, under sometension to enable compact winding and spooling.

In a novel approach that is represented in the following examples,collection and spooling methods are disclosed for use with theforcespinning of continuous fibers intended for use in textileapplications. The inventive subject matter overcomes the deficiency ofthe simple cotton-candy maker approach, which is not concerned withreducing the cotton-candy mats to a lengthy filamentous form, which maybe under some tension.

FIGS. 9A-13 show examples of collection systems that include a collectorthat has a surface for receiving streaming material from the spinneret.According to the inventive subject matter, a collector 318 may beassociated with and rotated in coordination with the spinneret'sspinning orifice. Alternatively, a stationary, non-orbital collector maybe stationary and located beneath the geometric center of the spinneret12 for a forcespinning system. The relative spin rates of the collectorand spinneret are coordinated so that the filamentous fiber is spooledonto the collector within a tension range that (1) achieves a desiredstate of compactness without straining the fiber to a breakage ordeformation state; and (2) avoids a slackness in the streams of formedor forming filaments as they are spooled so as not to whip and break ordeform the formed or forming filaments. In addition to the collector,the collection system may include other components, such as heaters androllers between the spinneret and collector, or subsequently inpost-processing of the fiber, to help manage tension and stream orfilament orientation.

The collection system would naturally include other components (notshown), such as electric motors for driving the collectors or othercomponents, sensors or registers for determining rates of rotation ofthe spinning components, or flow rates from jet outlet ports or formeasuring strain or loads of materials or components. The system mayalso include manual and/or computer controls, e.g., microprocessors andmemory with stored programs, for managing the rates of relative rates ofspinning and strain or load on the filaments being formed or formed.

FIGS. 9A-B are side and top schematic views of one possible collectionsystem for streams of fiber materials extruded from a spinneret. In thiscase, the collector 318, e.g., a drum or cylinder, orbitally rotatesaround the spinneret at some distance outwardly from the outlet port orports for the spinneret, which may be disposed on or along thecircumference of the spinneret. The collector is spaced sufficientlyfrom the spinneret so as to allow proper extrusion and drawing of thefilament or fiber via the centrifugal force of rotation. The distance ofthe collector from the outlet port, both radially and linearly, isdetermined by the outlet port size and the diameter of the fibercreated. This is because the jet of fiber-forming material 15 requires acertain distance of inertial draw to properly orient the polymer chainswithin the forming fiber. Other parameters to consider are theproperties of the material being extruded. For example, solutionviscosity and polymer chain alignment within the fiber are factors thataffect the extendable distance of the fiber using inertial force.Reducing the whipping effect of the fiber, as well as vortices caused bythe rotating collector, are also factors to consider. Any of theforegoing factors may be considered and addressed empirically by personsskilled in the art without undue experimentation. Thereby, appropriatespacing of the collector from the spinneret may be determinedempirically or otherwise, as well as relative rates of rotation for thecollector and spinneret, as discussed below.

Referring to the system of FIGS. 9A-B, the collector 318 is spaced awayfrom the outside circumference of the spinneret 12 and orbits thespinneret. The collector simultaneously is spinning around its ownlongitudinal axis as it orbits the spinneret. The collector's axis ofrotation is parallel to the spinneret's axis of rotation. The axialspinning of the collector causes the fiber to wind closely to andagglomerate around the collector, with filaments or fibers orientedgenerally parallel to one another. In this example, the rotatingspinneret and the collector can move relative to one another in the sameplane or a plane parallel to the spinneret. In this example, thecollector orbits a stationary spinneret (except for axial spinning).Alternatively, the spinneret can orbit the collector, which may bestationary. Either orbital arrangement allows for a uniform fibertake-up distance through an orbit.

The rate (rpm) at which the collector spins may be calculated ordetermined according to specific filament or fiber materials anddiameters. Spinning of the collector around its own axis creates tensionin the winding of fiber material. The fiber strength will determine theamount of tension required on the winding to properly wind the filamentor fiber about the collector. Breaking of the fiber can occur if the rpmof the collector is too fast, exceeding the tensile strength of thefiber or filament. If the rpm is too slow, the filament or fiber maywhip. This can cause weak points in the filament or fiber or it cancause the filament or fiber to break. Collection conditions may varyfrom material to material but can be established empirically, as notedabove. Those skilled in the art will understand that mechanisms requiredto guide the fiber onto the winding collector are numerous, and all suchmechanisms are contemplated, even if not explicitly disclosed herein.

A spinning collector with rpm's calibrated with a filament or fibertake-up speed equal to the slack in the inertial extension from thespinneret's outlet port may be achieved by other systems, not just thesystem of FIGS. 9A-B. In accordance with the inventive subject matter,FIGS. 10A-C are schematic views of other possible systems where acollector 418, 518 or 618 is disposed underneath the spinneret, incontrast to the forcespinning and collector system of FIGS. 9A-B, whichis spaced outwardly from the circumference of the spinneret. In thesystems of FIGS. 10A-C, a collector is disposed underneath the spinneretand may be stationary relative to the spinneret (except of thecollector's axial spinning). In the case of stationary collector, asuitable location would be directly below the geometric center of thespinneret, i.e., the spinneret's axis of rotation. FIGS. 10A-C showdifferent stationary spinning collectors 418, 518 or 618 disposed belowthe center of the spinneret 12. The collector is spinning around its ownlongitudinal axis but does not orbit the spinneret, as in the embodimentof FIGS. 9A-B. The longitudinal axis is parallel to the plane in whichthe spinneret rotates. That axis is perpendicular to the axis aroundwhich the spinneret rotates.

The collector of FIG. 10A is positioned over a backstop or guide 24 thatcan serve to deflect or feed the filament or fiber to the horizontalcollector aligned with and axially spinning over the back stop or guide.Accordingly, the fibers are collected in planes stacking horizontally tothe spinneret. FIG. 10B shows a collector disposed under the center ofthe spinneret that rotates around its own axis but does not orbit thespinneret. The filaments or fibers are spooled in planes stackingparallel to the plane in which the spinneret rotates. It is noted thatin the variations of FIGS. 10A-C, the collectors will collect filamentsor fibers, at times, with an unequal distribution across the length(horizontal alignment) or height (vertical alignment). In such cases,the collector systems may include moving or stationary guides andapparatus to move the filament or fiber along the spinning collector foruniform winding. Collectors of stationary type or moving within a planeor rotating around the spinneret can incorporate any geometric shape:cylinder, conical, or others without exclusion, as indicated by theconical or triangular or pyramidal collector representation of FIG. 10C,which is otherwise like the collector of FIG. 10B.

In the case of any collection and winding process the initial windingmay require a ramp up process. For this the spinneret may spin slowly toallow the filament or fiber to begin winding onto the collector.

After sufficient winding, the spinneret, the rotating collector (ifnon-stationary), and the spinning of the collector are ramped up to thenecessary rpm for the desired fiber characteristics. After properconditions are established, the system may provide a synergy ofcoordination and winding that does not require this pre-winding step.

In the case of a method that may require a pre-winding step, FIGS. 11,12, and 13 offer a range of unique and separate techniques. FIGS.11A-11C envision a cutout (not shown) below the spinneret where thefilament or fiber itself can be drawn through. However, it is envisionedthat a cutout may not be necessary, and the correct amount of tensioncan be created directly below the center of the spinneret. In thisembodiment, the filament or fiber is extruded from the rotatingspinneret 12 at a slow rpm, allowing the filament or fiber to be fedaround a rotating drum, cylinder, or wheel, or disk, which is referredto herein as a “driver” 26. This driver may be located directly belowthe geometric center of the rotating spinneret. From the spinneret, thefilament or fiber 15 is fed around the driver and then drawn onto acollector 18, located at some distance from the driver. Once affixed tothe collector, the rpm of the spinneret increases, as does the take-uprpm on the collector. At a predetermined spinneret rpm for filament orfiber extrusion (specific to, e.g., the fiber solution, orificediameter, and/or inertial extension required for the fiber), the rpm ofthe collector take-up is ramped up to a calculated rpm necessary toallow filament or fiber winding, with or without tension in the fiber.This process allows for the necessary filament or fiber slack in theextension of the filament or fiber from the spinneret 16 outlet port soas not to affect the quality of the filament or fiber. Because of theunique spinning of the spinneret, it is envisioned that an intermediatedriver may be pivoted 180 degrees and rotates 360 degrees in thevertical plane, horizontally (perpendicularly) to the axis of rotationof the spinneret. This allows equal tensioning of the drawn filament orfiber from any radial position that extends outwardly from the center ofthe spinneret's axis of rotation. The driver may be consideredfrictionless, or made essentially frictionless, to allow the collectionor tension to be sourced only from the collector.

Another possible embodiment uses a conical guide 124 positioned belowthe spinneret, as seen in FIG. 12. Using this scenario, a filament orfiber is led through the conical guide onto a roller. From the rollerbelow the conical guide, the filament or fiber is fed to the spinningcollector. A conical guide reduces the stress on the filament or fiberby guiding the fiber fluidly to the roller directly beneath the guide.The filament or fiber can be guided though the middle of the conicalguide or around the outside and then centered onto the driver.

Another possible embodiment, seen in FIG. 13, employs a rotating arm ofvaried geometry to guide the filament or fiber to the driver 26. In thisschematic, the geometry of the rotating arm, as well as distance fromthe spinneret, employs the same parameter considerations, as describedfor FIG. 9.

While a spinneret can orient fibers in the same direction, directionalair or other gas flow may be used to direct a stream of materialextruded from a spinneret or even a stationary extrusion device.Mechanisms for directing airflow include both positive and negativepressure system, e.g., fans, vacuums, and pressurized gas sources.Airflow may be directed at any desired angle against a stream ofmaterial so as to redirect the streams into a desired path andorientation. For example, the stream of material may be directed onto acontinuous belt. In this and any other embodiments, a movable flatsurface could be part of a continuous belt system that feeds the fibrousmaterial into rollers or spoolers or into other processing systems.

The foregoing embodiments are not meant to be an exhaustive list of themethodologies used to create and capture continuous fibers from aforcespinning apparatus. From the teachings herein, persons skilled inthe art may use forcespinning to produce and collect continuous fibersfor any application in woven or knitted goods or any other applicationthat uses continuous fibers.

Definitions (as Generally Described in Literature for the Outdoor andTextile Industries):

Waterproof/breathable (composite fabric): a textile (knit or woven)composite that withstands water penetration of a certain pressure asdefined by different standards but it also breathable, as measured bydifferent standards allowing moisture to pass through the compositematerial. The composite can contain 1 textile layer and the waterproofbreathable membrane (defined as a 2 layer waterproof-breathablecomposite), or the waterproof-breathable membrane can be sandwichedbetween 2 textile layers (defined as a 3 layer waterproof-breathablecomposite). In the case of a 2.5 layer waterproof-breathable composite,the membrane typically has a print applied on the membrane surfaceopposite the outer textile side. This print can be a color, design,and/or include functional particles in any pattern. Textile layers canbe woven or knitted structures of any fiber type (natural, synthetic,bio-based, biodegradable) or blends of any fiber types. All seams aresealed using seam tape to ensure waterproofness.

Waterproof/Breathable Membrane: A flexible material that is (1)waterproof, and (2) breathable to moisture, according selectedstandards. Membranes can be hydrophilic, hydrophobic, monolithic, ormicroporous. A bi-component membrane combines two layers, for exampleGORE-TEX ePTFE membranes and another layer of material.

Air Permeability: Ability of a textile, membrane, or composite to allowair to penetrate through the material; measured in CFM, cubic feet perminute.

Moisture Vapor Breathability/Vapor Permeability: Referred to the abilityof a textile, waterproof/breathable membrane, or composite to allowmoisture (liquid or water vapor) to pass through the material.

Hardshell (2L, 2.5L, 3L): A waterproof-breathable composite consistingof multiple layers 2, 2.5, or 3L that achieve a high degree ofwindproofness. The outer layer is typically a more material, such as aNylon fabric. A typical fabric constriction is a ripstop.

Softshell: Textile composite with high water resistance, however,focusing on wind blocking. Wind block may be attained using a waterproofbreathable membrane (sandwiched between two textile layers) or using anadhesive or glue to affix 2 textiles or substrates together. The glue isnot air permeable and therefore meters air penetration in the composite.Textile fabrics are typically softer woven and knitted fabrics, hencethe term softshell. By manipulating the design features for each textilecomposite, the air permeability can range from between 0 to 100% windblock.

Nanofiber: Defined as fibers with diameters between 100-1000 nanometers.Nanofibers provide high surface area and unique properties at thenanoscale level.

Nonwoven: fabric-like materials that are made from fibers bondedtogether by something other than a weaving process, such as chemical,heat, mechanical, or solvent processes. The fibers are entangled,creating a web structure. The entanglement creates pores between fibers,providing some degree of air permeability.

Persons skilled in the art will recognize that many modifications andvariations are possible in the details, materials, and arrangements ofthe parts and actions which have been described and illustrated in orderto explain the nature of the inventive subject matter, and that suchmodifications and variations do not depart from the spirit and scope ofthe teachings and claims contained therein.

All patent and non-patent literature cited herein is hereby incorporatedby references in its entirety for all purposes.

1.-13. (canceled)
 14. A bulk fill material suitable for use as aninsulative or cushioning material in footwear, outdoor apparel, and/oroutdoor equipment, the bulk fill material comprising: a plurality ofdiscrete units comprising clusters or loose webs of fibers, the fiberscomprising superfine fibers and/or fibers in a range of 1 to 5 denier;the fibers being entangled to form the clusters or loose webs.
 15. Thebulk fill material of claim 14 wherein the clusters or webs of fiberscomprise a plurality of fibers, the fibers each being a multinode fiberstructure formed of fiber material formed into a unitary, multinodefiber structure, the multinode fiber structures being agglomerated asclusters or webs.
 16. The bulk fill material of claim 14 wherein acombination of fiber types are included in the clusters or webs, thefiber types being selected from one or more of the following fiber typevariations: (1) variation in fiber material and/or (2) variation infiber diameters or cross-sectional geometries.
 17. The bulk fillmaterial of claim 16 wherein the fibers in a cluster or web comprisesuperfine fibers.
 18. The bulk fill material of claim 17 wherein thefibers in the clusters or webs comprise a blend of superfine fibers andfibers having of at least 1 denier.
 19. The bulk fill material of claim14 wherein the fill material has a fill power equivalent of 450 to1,000.
 20. The bulk fill material of claim 14 wherein the average fiberdiameter is less than 100 nm.
 21. The bulk fill material of claim 14wherein the average fiber diameter is less than 50 nm.
 22. The bulk fillmaterial of claim 15 wherein the fibers comprise fibers having tubularor otherwise non-solid cores.
 23. A construct comprising an item offootwear, outdoor apparel, and/or outdoor equipment, the item containinga bulk fill material comprising: a plurality of discrete unitscomprising clusters of fibers, the fibers comprising superfine fibersand/or fibers in a range of 1 to 5 denier; and the fibers beingentangled to form the clusters.
 24. The construct of claim 23 whereinthe item comprises an item of apparel.
 25. The construct of claim 23wherein the item comprises an item of outdoor equipment that is asleeping bag.
 26. The construct of claim 23 wherein the item comprisesan item of footwear.
 27. A construct comprising an item of footwear,outdoor apparel, and/or outdoor equipment, the item containing a bulkfill material comprising: a plurality of loose webs of fibers, thefibers comprising superfine fibers and/or fibers in a range of 1 to 5denier; the fibers being entangled to form the loose webs.
 28. Theconstruct of claim 27 wherein the item comprises an item of apparel. 29.The construct of claim 27 wherein the item comprises an item of outdoorequipment that is a sleeping bag.
 30. The construct of claim 27 whereinthe item comprises an item of footwear.